JP2011230557A - Interior component for vehicle and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an interior component for a vehicle which can be easily manufactured and exhibits favorable appearance while being improved in the accuracy of edge processing at an end subjected to folding processing.SOLUTION: The interior component 1 for the vehicle comprises a base material 2 including a first skin layer 2A, a resin foamed layer 2B and a second skin layer 2C in this order. The surface of the second skin layer side is used as a design surface. An end of the interior component for a vehicle is formed into a flat tongue 3 by pressing the base material from the first skin layer side to the second skin layer side. In a portion corresponding to the base end of the tongue in the above interior component, an inclined portion 4 is formed with the first skin layer side serving as an inclined face. The inclined portion is configured in such a manner that the first skin layer approaches the second skin layer toward the base end of the tongue. The tongue is folded into the first skin layer side.

Description

  The present invention relates to a vehicle interior part and a method for manufacturing the same. More specifically, the present invention relates to an interior part for a vehicle that can be easily manufactured and has a good appearance while improving the terminal accuracy of a bent end, and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, an injection molding method in which a molten resin is injected and filled in a space formed between molds has been widely used as a method for manufacturing vehicle interior parts such as door trims. According to this injection molding method, a molded product having a complicated shape can be produced in large quantities, and the product appearance is also excellent.

  On the other hand, the weight reduction of parts for improving the fuel efficiency of vehicles is being promoted, and the demand for weight reduction of interior parts for vehicles is also increasing. However, in the above-described injection molding method, since it is difficult to manufacture a molded product having a predetermined thickness or less, there is a limit to reducing the weight. For this reason, a method of press-molding a base material provided with a resin foam layer has been adopted as a new method for manufacturing a vehicle interior product.

  In the method of manufacturing interior parts for vehicles by press molding, the outer peripheral edge of the heat-softened base material is fixed, press-molded with a press-molding die, and unnecessary portions at the end are trimmed. . In addition, in this manufacturing method by press molding, in order to improve the appearance of the end portion such as the outer peripheral edge, a flat wrapping sheet is formed at the end portion, and the wrapping sheet is wound on the back surface side. It is known (see, for example, Patent Document 1).

JP 2006-346945 A

However, in the case of an interior part for a vehicle manufactured as described in Patent Document 1, since the angle at which the entrainment white is bent is large, the outer side of the bent part is whitened or wrinkles are generated on the inner side. There was a problem that defects occurred.
Further, as shown in FIG. 10, in the terminal of the conventional interior part 101, the entrainment white 103 is floated, specifically, the bulge of the distance L occurs due to the floating at the terminal. There was a problem that the appearance (terminal accuracy) was not so good.

  The present invention has been made in view of the above circumstances, and it can be easily manufactured, and it improves the terminal accuracy of the end portion subjected to the bending process, and has a good appearance, and its manufacture. It aims to provide a method.

  In order to solve the above-mentioned problems, the invention according to claim 1 is an interior part for a vehicle comprising a base material provided with a first skin layer, a resin foam layer and a second skin layer in order, wherein the second skin The surface on the layer side is a design surface, and a flat tongue piece is formed at the end of the interior part for the vehicle by squashing the base material from the first skin layer side to the second skin layer side. An inclined portion having an inclined surface on the first skin layer side is formed at a portion of the interior part for a vehicle positioned at the proximal end of the tongue piece portion, and the inclined portion is a base of the tongue piece portion. The gist is that the first skin layer approaches the second skin layer as it approaches the end, and the tongue piece is bent toward the first skin layer.

  The invention according to claim 2 is summarized in that, in claim 1, the tongue piece portion is further bent along the inclined surface of the inclined portion.

  According to a third aspect of the present invention, in the second aspect, the tongue piece portion is in contact with the first contact portion that contacts the inclined surface and the flat surface on the first skin layer side of the interior part for a vehicle. And a second abutting portion that comes into contact.

  Invention of Claim 4 consists of a base material provided with a 1st skin layer, a resin foam layer, and a 2nd skin layer in order, The manufacture of the interior component for vehicles by which the surface by the side of the said 2nd skin layer was made into the design surface. In the method, the base material is crushed from the first skin layer side to the second skin layer side by press molding so that the base material is placed on the first skin layer side at an end of the vehicle interior part. A flat tongue piece crushed from the second skin layer to the second skin layer side, and the first skin layer side is inclined at a portion of the vehicle interior part located at the base end of the tongue piece portion A press molding step for forming the inclined portion, and a bending step for bending the tongue piece portion toward the first skin layer so that the tongue piece portion is along the inclined surface of the inclined portion. This is the gist.

  According to a fifth aspect of the present invention, in the fourth aspect, in the press molding step, the form formed by the inclined surface and the tongue piece portion is substantially V-shaped when viewed from the side of the vehicle interior part. The gist is to perform press molding so as to obtain a shape.

  The invention according to claim 6 includes the vacuum forming step according to claim 4 or 5, wherein after the press forming step, the inclined surface is extended by vacuum forming to thicken the resin foam layer. This is the gist.

  According to the interior part for a vehicle of the present invention, a flat tongue piece formed by crushing the base material from the first skin layer side to the second skin layer side is formed at the end thereof. In addition, an inclined portion having an inclined surface on the first skin layer side is formed in a portion of the interior part for a vehicle located at the base end of the tongue piece. The inclined portion is configured such that the first skin layer approaches the second skin layer as it approaches the proximal end of the tongue piece. Further, the tongue piece is bent toward the first skin layer. With such a configuration, for example, as shown in FIG. 11, even when the tongue piece 203 of the interior part 201 is bent to the first skin layer side, swelling of the terminal is suppressed, and the terminal Appearance is good (terminal accuracy is improved).

  Further, when the tongue piece is bent along the inclined surface of the inclined portion, the terminal is further prevented from swelling and the appearance of the terminal is improved (terminal accuracy is improved).

  Furthermore, when the said tongue piece part is provided with the 1st contact part contact | abutted to the said inclined surface, and the 2nd contact part contact | abutted to the flat surface by the side of the said 1st skin layer of this vehicle interior component. In addition, the area of the tongue piece portion in contact with the inclined surface and the flat surface can be increased. Thereby, when bonding a tongue piece part and an inclined surface and a flat surface, it can fix more reliably.

  According to the method for manufacturing an interior component for a vehicle of the present invention, the base material is squeezed from the first skin layer side to the second skin layer side by press molding so that the base material is attached to the end of the vehicle interior component at the first skin. A flat tongue piece squeezed from the layer side to the second skin layer side is formed, and the first skin layer side is inclined at a portion of the vehicle interior part located at the base end of the tongue piece part. A press forming step for forming the inclined portion, and a bending step for bending the tongue piece portion toward the first skin layer so that the tongue piece portion follows the inclined surface of the inclined portion. As a result, for example, as shown in FIG. 11, even when the tongue piece 203 of the interior part 201 is bent to the first skin layer side, swelling of the terminal is suppressed, and the appearance of the terminal is good. (Terminal accuracy is improved). Moreover, a tongue piece part and an inclined part can be formed easily.

  Furthermore, in the press molding step, the press molding is performed such that the shape formed by the inclined surface and the tongue piece is substantially V-shaped when viewed from the side of the vehicle interior part. Can reduce the bending angle when the tongue piece is bent, so that it is possible to manufacture a vehicular interior part having a good appearance in which the bent portion of the tongue piece is not whitened, cracked, or wrinkled. it can.

  Furthermore, after the press molding step, the inclined surface can be efficiently molded by providing a vacuum molding step of extending the inclined surface by vacuum forming and thickening the resin foam layer.

The present invention will be further described in the following detailed description with reference to the drawings referred to, with reference to non-limiting examples of exemplary embodiments according to the present invention. Similar parts are shown throughout the several figures.
It is a figure which shows the outline of the vehicle interior component which concerns on a present Example. FIG. 2 is a partial cross-sectional view taken along the line II of FIG. 1. It is a fragmentary longitudinal cross-sectional view of the vehicle interior component according to the present embodiment. It is explanatory drawing for demonstrating the manufacturing method of the vehicle interior component which concerns on a present Example. It is explanatory drawing for demonstrating the manufacturing method of the vehicle interior component which concerns on a present Example. It is explanatory drawing for demonstrating the manufacturing method of the vehicle interior component which concerns on a present Example. It is explanatory drawing for demonstrating the manufacturing method of the vehicle interior component which concerns on a present Example. It is explanatory drawing for demonstrating the manufacturing method of the vehicle interior component which concerns on a present Example. It is a fragmentary longitudinal cross-sectional view of the interior part for vehicles concerning other embodiments. It is a figure which shows the example of the conventional vehicle interior components, Comprising: It is a fragmentary longitudinal cross-sectional view for demonstrating the floating state of a terminal. It is a fragmentary longitudinal cross-sectional view for demonstrating the floating state of the terminal of the vehicle interior components in which the inclination part is formed.

  The items shown here are exemplary and illustrative of the embodiments of the present invention, and are the most effective and easy-to-understand explanations of the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to illustrate the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention. It will be clear to those skilled in the art how it is actually implemented.

1. Vehicle interior parts Embodiment 1 The vehicle interior component according to the present invention is a vehicle interior component composed of a base material provided with a first skin layer, a resin foam layer, and a second skin layer in order,
The surface on the second skin layer side is a design surface, and a flat tongue piece is formed at the end of the interior part for a vehicle by squashing the base material from the first skin layer side to the second skin layer side. An inclined portion having an inclined surface on the first skin layer side is formed in a portion of the vehicle interior part located at the proximal end of the tongue piece, and the inclined portion approaches the proximal end of the tongue piece. Accordingly, the first skin layer approaches the second skin layer, and the tongue piece is bent toward the first skin layer (see, for example, FIG. 3).
Examples of the vehicle interior parts include vehicle interior parts such as a door trim (see, for example, FIG. 1), an instrument panel, a roof trim, a deck board, a package tray, and the like.

  As long as the “base material” includes the first skin layer, the resin foam layer, and the second skin layer in this order, the structure, size, shape, material, and the like are not particularly limited. As this base material, for example, it can be in the form of a sheet formed by laminating the above layers. Further, the interior part for a vehicle made of this base material has a surface on the second skin layer side as a design surface. In the base material, another layer may be interposed between one or both of the first skin layer and the resin foam layer and between the resin foam layer and the second skin layer.

Examples of the material for the first skin layer and the second skin layer include polypropylene (PP), polyethylene (PE), polyvinyl chloride (PVC), polystyrene (PS), polyvinyl acetate (PVAc), and polytetrafluoroethylene. Examples thereof include thermoplastic synthetic resins such as (PTFE), acrylonitrile butadiene styrene (ABS), and polyethylene terephthalate (PET). The first skin layer and the second skin layer are usually in the form of a sheet made of these thermoplastic resins.
As the material of the resin foam layer, for example, the same thermoplastic resin as that of the first skin layer and the second skin layer can be employed. This resin foam layer is usually in the form of a sheet that is foamed by adding a foaming agent to these thermoplastic resins.

  As long as the “tongue piece” is formed in an end portion of the interior part for the vehicle and has a flat shape in which the base material is crushed from the first skin layer side to the second skin layer side, its size, number, etc. Is not particularly limited. Moreover, this tongue piece part is bend | folded to the 1st skin layer side, The bending angle (theta) 1 can be 30-85 degrees, for example, Preferably, it can be 45-60 degrees (for example, , See FIG. Moreover, it is preferable that this bending is simultaneously performed when the tongue piece is formed into a flat shape by press molding or the like.

The “inclined portion” is formed in a portion of the interior part for a vehicle that is located at the proximal end of the tongue piece portion, and the first skin layer side is an inclined surface, and the first skin layer is closer to the proximal end of the tongue piece portion. As long as one skin layer is configured to approach the second skin layer, the size, number, etc. thereof are not particularly limited. The inclination angle θ2 of the inclined surface of the inclined portion can be, for example, 30 to 85 °, and preferably 45 to 60 ° (see, for example, FIG. 3).
Here, the angle θ3 formed by the surface on the first skin layer side of the tongue piece and the surface on the first skin layer side of the inclined portion can be, for example, 10 to 90 °, preferably The angle may be 45 to 90 °, more preferably 45 to 60 ° (see, for example, FIG. 3).

  Here, the first embodiment. For example, the tongue piece can be bent along the inclined surface of the inclined portion (see, for example, FIG. 2). The bent tongue piece portion may be bonded to the inclined surface of the inclined portion by, for example, an adhesive or heat welding, or may not be bonded but only bent along the inclined surface.

  Here, the tongue piece portion includes, for example, a first abutting portion that abuts on the inclined surface, and a second abutting portion that abuts on a flat surface on the first skin layer side of the vehicle interior part. (For example, refer to FIG. 8 or the like). The portion on the tip side of the tongue piece may be bonded to the flat surface by, for example, an adhesive or heat welding, or may not be bonded but only bent along the flat surface.

2. Method for Manufacturing Interior Parts for Vehicle This Embodiment 2. The method for manufacturing an interior component for a vehicle according to the present invention includes a base material including a first skin layer, a resin foam layer, and a second skin layer in order, and the interior surface component for a vehicle having a surface on the second skin layer side as a design surface. A manufacturing method comprising:
By flattening the base material from the first skin layer side to the second skin layer side by press molding, the flat surface is crushed from the first skin layer side to the second skin layer side at the end of the vehicle interior part. Forming a tongue-shaped tongue portion and forming an inclined portion having an inclined surface on the first skin layer side in a portion located at the base end of the tongue piece portion of the vehicle interior part (for example, FIG. 4 and 5), and a bending step (see, for example, FIG. 2) for bending the tongue piece portion toward the first skin layer so that the tongue piece portion is along the inclined surface of the inclined portion. Features.

  In the press molding step, for example, press molding can be performed such that the shape formed by the inclined surface and the tongue piece portion is substantially V-shaped when viewed from the side of the vehicle interior part (for example, , See FIG.

  Here, the second embodiment. The vehicle interior part manufacturing method according to the present invention can include, for example, a vacuum forming step of extending the inclined surface by vacuum forming and thickening the resin foam layer after the press forming step (for example, (See FIGS. 5 and 6).

  Hereinafter, the present invention will be described more specifically with reference to the drawings. In this embodiment, as an interior part for a vehicle according to the present invention, as shown in FIG. 1, a door trim 1 attached to a surface of the door on the vehicle interior side is illustrated.

(1) Configuration of Vehicle Interior Parts As shown in FIG. 2, a door trim 1 that is a vehicle interior part according to this embodiment includes a first skin layer 2A, a resin foam layer 2B, and a second skin layer 2C in this order. It consists of a substrate 2. At the end of the door trim 1, a flat tongue piece 3 is formed by squashing the base material 2 from the first skin layer 2A side to the second skin layer 2C side. In addition, an inclined portion 4 having an inclined surface on the first skin layer 2 </ b> A side is formed in a portion of the door trim 1 positioned at the proximal end of the tongue piece portion 3. The inclined portion 4 is configured such that the first skin layer 2A approaches the second skin layer 2C as the base end of the tongue piece portion 3 is approached. Thereby, the tongue piece part 3 and the inclined surface of the inclined part 4 have a groove shape with a substantially V-shaped cross section. The door trim 1 has a design surface on the second skin layer 2C side. That is, the surface on the second skin layer 2C side of the door trim 1 is a surface on the vehicle interior side, and the surface on the first skin layer 2A side is a surface attached to the door panel of the vehicle.

  As shown in FIG. 2, the tongue piece portion 3 is bent toward the first skin layer 2 </ b> A and is in contact with the inclined surface of the inclined portion 4. As shown in FIG. 3, the tongue piece 3 before being bent is previously bent at a predetermined bending angle θ1 (for example, about 60 °). The inclined surface of the inclined portion 4 is set to a predetermined inclination angle θ2 (for example, about 60 °). The angle formed between the surface on the first skin layer 2A side of the tongue piece 3 and the inclined surface of the inclined portion 4 is θ3 (for example, about 60 °). That is, as shown in FIG. 3, the door trim 1 shown in FIG. 2 is further bent along the inclined surface of the inclined portion 4 having an inclination angle of θ2 by further bending the tongue piece portion 3 that has been previously bent by θ1 by an angle θ3. It is in a folded state.

(2) Manufacturing Method for Vehicle Interior Parts Next, a manufacturing method for the door trim 1 which is the vehicle interior part having the above-described configuration will be described.
First, as shown in FIG. 4, the heat-softened sheet-like base material 2 is placed between press-molding dies 5 and 6. At this time, the portion of the outer peripheral edge that protrudes from the press-molding dies 5 and 6 of the base material 2 is fixed by fixing means (not shown). Next, as shown in FIG. 5, the base material 2 is press-molded by press-molding dies 5 and 6 (press molding process). Thereby, the part equivalent to the tongue piece part 3 and the inclination part 4 is formed. In addition, by the press molding step, the form formed by the tongue piece portion 3 and the inclined surface of the inclined portion 4 becomes substantially V-shaped when viewed from the side of the door trim 1. Then, as shown in FIG. 6, the resin foam layer 2B is thickened by evacuating the space S between the press-molding dies 5 and 6 (vacuum forming step). Thereby, the plate | board thickness of the base material 2 becomes thicker than shaping | molding, while an inclined surface is extended and it shape | molds in a required shape. Thereafter, as shown in FIG. 7, the base material 2 molded from the press-molding dies 5 and 6 is removed, and unnecessary portions are trimmed by the trimming blade 7 as shown in FIG. Thereby, the door trim 1 shown in FIG. 3 is obtained. Furthermore, it passes through the bending process which bends the tongue piece part 3 along the inclined surface of the inclined part 4, and becomes the door trim 1 shown in FIG. In this embodiment, the tongue piece 3 and the inclined surface of the inclined portion 4 are bonded.

  (3) Effects of the embodiment

  As described above, in the door trim 1 of the present embodiment, the flat tongue piece portion 3 is formed by squashing the base material 2 from the first skin layer 2A side to the second skin layer 2C side at the end portion thereof. In addition, an inclined portion 4 having an inclined surface on the first skin layer 2 </ b> A side is formed in a portion of the door trim 1 that is positioned at the proximal end of the tongue piece portion 3. The inclined portion 4 is configured such that the first skin layer 2A approaches the second skin layer 2C as the base end of the tongue piece portion 3 is approached. Furthermore, the tongue piece 3 is bent toward the first skin layer 2A. With such a configuration, even if the tongue piece portion 3 bent to the first skin layer 2A side is lifted, the terminal bulge is suppressed and the appearance of the terminal is improved (terminal accuracy is improved).

  Furthermore, since the tongue piece part 3 is bent along the inclined surface of the inclined part 4, the swelling of the terminal is suppressed, and the appearance of the terminal is improved (terminal accuracy is improved).

  Further, since the tongue piece 3 and the inclined surface of the inclined portion 4 are formed in a groove shape having a substantially V-shaped cross section, when the tongue piece 3 is bent until it comes into contact with the inclined surface of the inclined portion 4, The door trim 1 can be bent with the apex portion as the starting point of bending, and the outer edge of the door trim 1 can be realized without causing defects such as undulations at the edges.

  Moreover, in the manufacturing method of the vehicle interior component of the present embodiment, the base material 2 is crushed by press molding from the first skin layer 2A side to the second skin layer 2C side, so that the base material 2 is applied to the end portion of the door trim 1. Is formed into a flat tongue piece 3 that is crushed from the first skin layer 2A side to the second skin layer 2C side, and a portion of the door trim 1 that is located at the base end of the tongue piece portion 3 has a first skin. A press molding step for forming the inclined portion 4 having the inclined surface on the side of the layer 2A, and bending for bending the tongue piece portion 3 to the first skin layer 2A side so that the tongue piece portion 3 follows the inclined surface of the inclined portion 4; And a process. Thereby, even if floating occurs when the tongue piece portion 3 is bent toward the first skin layer 2A, the terminal bulge is suppressed, and the appearance of the terminal is improved (terminal accuracy is improved). Moreover, the tongue piece part 3 and the inclination part 4 can be formed easily.

  Further, in the press molding process, the shape formed by the inclined surface and the tongue piece 3 is press-molded so that it is substantially V-shaped with an acute angle when viewed from the side of the door trim 1, and the V-shaped By bending the tongue piece 3 along the inclined surface of the inclined portion 4 with the vertex of the bent portion as a starting point, the bending angle θ3 when the tongue piece 3 is bent can be reduced. Thus, the door trim 1 having a good appearance without wrinkles or the like can be manufactured.

  Furthermore, since the vacuum forming step of extending the inclined surface is performed by vacuum forming and thickening the resin foam layer 2B after the press forming step, the inclined surface can be efficiently formed.

  In addition, in this invention, it can restrict to what is shown to said specific Example, It can be set as the Example variously changed within the range of this invention according to the objective and the use. That is, in the above-described embodiment, an example in which the tongue piece portion 3 is bent until it comes into contact with the inclined surface of the inclined portion 4 is not limited to this. For example, as shown in FIG. It is good also as the tongue piece part 23 provided with the 1st contact part 23A contact | abutted to an inclined surface, and the 2nd contact part 23B contact | abutted to the flat surface by the side of the 1st skin layer 2A of the vehicle interior components 21. By doing in this way, the area of the tongue piece part which contact | connects the inclined surface and the flat surface by the side of the 1st skin layer of vehicle interior components can be enlarged. As a result, when the tongue piece portion is bonded to the inclined surface and the flat surface, the tongue piece portion can be more reliably fixed.

  The foregoing examples are for illustrative purposes only and are not to be construed as limiting the invention. Although the invention has been described with reference to exemplary embodiments, it is to be understood that the language used in the description and illustration of the invention is illustrative and exemplary rather than limiting. As detailed herein, changes may be made in its form within the scope of the appended claims without departing from the scope or spirit of the invention. Although specific structures, materials and examples have been referred to in the detailed description of the invention herein, it is not intended to limit the invention to the disclosure herein, but rather, the invention is claimed. It covers all functionally equivalent structures, methods and uses within the scope.

  The present invention is not limited to the embodiments described in detail above, and various modifications or changes can be made within the scope of the claims of the present invention.

  DESCRIPTION OF SYMBOLS 1; Vehicle interior components (door trim), 21; Vehicle interior components, 2; Base material, 2A; 1st skin layer, 2B; Resin foam layer, 2C; 2nd skin layer, 3,23; 4; Inclined portions, 5 and 6; Die for press molding, 7; Trimming blade, 23A; First contact portion, 23B; Second contact portion, L; Distance, S;

Claims (6)

An interior part for a vehicle comprising a base material provided with a first skin layer, a resin foam layer and a second skin layer in order,
The surface on the second skin layer side is a design surface,
A flat tongue piece formed by crushing the base material from the first skin layer side to the second skin layer side is formed at an end of the interior part for a vehicle.
An inclined portion having an inclined surface on the first skin layer side is formed in a portion of the interior part for a vehicle located at the base end of the tongue piece portion,
The inclined part is configured such that the first skin layer approaches the second skin layer as it approaches the proximal end of the tongue piece part,
The vehicle interior part, wherein the tongue piece is bent toward the first skin layer.   Furthermore, the interior part for vehicles of Claim 1 in which the said tongue piece part is bend | folded along the said inclined surface of the said inclined part.   The tongue portion includes a first abutting portion that abuts on the inclined surface, and a second abutting portion that abuts on a flat surface on the first skin layer side of the vehicle interior part. Vehicle interior parts as described. It consists of a base material provided with a first skin layer, a resin foam layer and a second skin layer in order,
A method for manufacturing an interior part for a vehicle in which the surface on the second skin layer side is a design surface,
By crushing the base material from the first skin layer side to the second skin layer side by press molding, the base material is applied from the first skin layer side to the second skin at the end of the vehicle interior part. An inclined portion that forms a flat tongue piece that is crushed to the layer side, and that has an inclined surface on the first skin layer side at a portion of the interior part for a vehicle that is positioned at the base end of the tongue piece portion Press forming process to form,
A bending step of bending the tongue piece portion toward the first skin layer so that the tongue piece portion is along the inclined surface of the inclined portion;
A method for manufacturing an interior part for a vehicle, comprising:   5. The press forming step according to claim 4, wherein in the press forming step, press forming is performed such that a shape formed by the inclined surface and the tongue piece portion is substantially V-shaped when viewed from the side of the vehicle interior part. Manufacturing method of interior parts for vehicles.   The method for manufacturing an interior part for a vehicle according to claim 4 or 5, further comprising a vacuum forming step of extending the inclined surface by vacuum forming and thickening the resin foam layer after the press forming step.

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